Echo HCA-2500 Instrucciones de montaje

HCA-250015-23C-00 1

lNTRODUCTION

We are constantly working on technical

improvement of our products. For this reason,

technical data, equipment and design are

subject to change without notice. All

specifications, illustrations and directions in

this SERVICE DATA are based on the latest

products information available at the time of

publication.

CONTENTS page

1 SERVICE INFORMATION ............................. 2

1-1 Specification...............................................2

1-2 Technical data ............................................3

1-3 Torque limits ...............................................4

1-4 Special repairing materials ........................4

1-5 Service limits..............................................5

1-6 Special tools...............................................6

2 EMISSION ADJUSTMENT GUIDE ...............7

2-1 General adjusting rules ..............................7

2-2 Presetting idle adjust screw, L mixture needle

and H mixture needle........................................7

2-3 Adjusting carburettor..................................9

Reference No. 15-23C-00

ISSUED: 200606

INDEX

SERVICE INFORMATION HCA-2500

1 SERVICE INFORMATION

1-1 Specifications

Dimensions Length mm(in) 2330 (91.7)

Width mm(in) 225 (9.3)

Height mm(in) 225 (9.3)

Dry weight kg(lb) 6.4 (14.1)

Engine Type KIORITZ, air-cooled, two-stroke, single cylinder

Rotation Anticlockwise as viewed from the output end

Displacement cm3(in3) 23.6 (1.440)

Bore mm(in) 34.0 (1.339)

Stroke mm(in) 26.0 (1.024)

Compression ratio 6.3

Carburettor Type Rotary type : Diaphragm, horizontal-draught, with primer (purge pump)

Model Walbro WT-424C

Venturi size-Throttle bore mm(in) 7.9 - 12.7 (0.31 - 0.5)

Ignition Type CDI (Capacitor discharge ignition) system

with electronic speed governor

Spark plug BPMR7A

Starter Type Automatic rewind

Rope diameter x length mm(in) 3.0 x 1000 (0.12 x 39.4)

Fuel Type Premixed two-stroke fuel

Mixture ratio 50 : 1 (2 %)

Petrol Minimum 89 octane petrol (RON)

Two-stroke air cooled engine oil ISO-L-EGD (ISO/CD13738), JASO FC

Tank capacity L (U.S.fl.oz.) 0.4 (13.5)

Clutch Type Centrifugal, 2 - shoe slide

Handle Type Front Rubber grip

Rear Rubber grip with throttle trigger

Drive shaft Type Flexible

Inner shaft: Diameter - Length mm(in) 6.15 - 1522 (0.24 - 60.0)

Housing OD -ID mm(in) 25 - 22 (0.98 - 0.87)

(Main pipe) Length mm(in) 1500 (59.0)

Gear case Reduction ratio 3.95

Gear tooth Spiral bevel

Lubrication Lithium based grease

Cutter Type Double reciprocating, double edge blade

Called Length mm(in) 450 (18)

Pitch mm(in) 35.0 (1.38)

Height mm(in) 21.0 (0.83)

Thickness mm(in) 2.5 (0.098)

Articulate adjustment 180°variable at 15°pitch + storage position

OD: Outer diameter. ID: Inner diameter.

SERVICE INFORMATIONHCA-2500 3

1-2 Technical data

Engine

Idling speed r/min 2400 - 3200

Operating speed r/min 7000 - 8000

Wide open throttle speed r/min 9000 - 10500

Clutch engagement speed r/min 3700 - 4300

Compression pressure MPa (kgf/cm2) (psi) 0.94 (9.6) (136)

Ignition system

Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)

Minimum secondary voltage at 1500 r/min kV 15

Primay coil resistance Ω200 - 400

Secondary coil resistance kΩ1.3 - 1.8

Pole shoe air gaps mm(in) 0.30 - 0.40 (0.012 - 0.016)

Ignition timing at 3000 r/min °BTDC 29

at 8000 r/min °BTDC 28

at 9000 r/min °BTDC 12

Carburettor

Idle adjust screw initial setting turn in* 1 1/2

L mixture needle initial setting turn back 2 1/4

Hmixture needle initial setting turn back 3 1/4

Test Pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0)

Metering lever height mm(in) 1.65 (0.065) lower than diaphragm seat

BTDC: Before top dead centre.

* Set idle speed screw to contact throttle plate before initial setting.

SERVICE INFORMATION HCA-2500

1-3 Torque limits

Descriptions Size kgf•cm N•m in•lbf

Starter Pawl carrier M 8 80 - 100 8 - 10 70 - 85

system Starter case M 4* 22 - 28 2.2 - 2.8 19 - 24

Ignition Ignition coil (CDI module) M 4* 38 - 55 3.8 - 5.5 35 - 50

system Spark plug M 14 150 - 170 15 - 17 130 - 150

Fan cover M 4* 38 - 55 3.8 - 5.5 35 - 50

Fuel Carburettor insulator M 5* 30 - 40 3 - 4 26 - 35

system Carburettor M 5 35 - 45 3.5 - 4.5 30 - 40

Throttle wire housing nut M 6 6 - 10 0.6 - 1.0 5 - 9

Fuel tank M 5* 27 - 32 2.7 - 3.2 23 - 28

Clutch Clutch hub M 8 180 - 200 18 - 20 155 - 175

Engine Crankcase M 5 75 - 85 7.5 - 8.5 65 - 75

Cylinder M 5 75 - 85 7.5 - 8.5 65 - 75

Cylinder cover M 4* 35 - 45 3.5 - 4.5 30 - 40

Muffler M 5 55 - 65 5.5 - 6.5 50 - 55

Top guard M 5* 25 - 35 2.5 - 3.5 22 - 30

Regular bolt, nut and screw M 3 6 - 10 0.6 - 1.0 5 - 9

M4 15 - 25 1.5 - 2.5 13 - 22

M 5 25 - 45 2.5 - 4.5 22 - 40

M 6 45 - 75 4.5 - 7.5 40 - 65

M 8 110 - 150 11 - 15 95 - 130

M 10 210 - 300 21 - 30 180 - 260

* Apply thread locking sealant. (See below)

1-4 Special repairing materials

Material Location Remarks

Grease Drive shaft

Gear case

Rewind spring Lithium based grease

Starter center post

Thread locking sealant Starter case

Ignition coil

Fan cover

Carburettor insulators Loctite #222, ThreeBond 1342 or equivalent

Fuel tank

Cylinder cover

Top guard

Latch Loctite #675 or equivalent

PTO shaft

SERVICE INFORMATIONHCA-2500 5

5K193 5K228 5K229 5K230

5K231 5K016 5K042 5K194

012345678910 11 12

0510

5K171 5K232

1-5 Service limits

ABCD

EFGH

Description mm (in)

A Cylinder bore When plating is worn and aluminium can be seen

B Piston outer diameter Min. 33.91 (1.335)

C Piston pin bore Max. 8.030 (0.3161)

D Piston ring groove Max. 1.6 (0.063)

E Piston ring side clearance Max. 0.1 (0.004)

F Piston pin outer diameter Min. 7.970 (0.3138)

G Piston ring width Min. 1.45 (0.057)

H Piston ring end gap Max. 0.5 (0.02)

K Crankshaft runout Max. 0.05 (0.002)

L Clutch drum bore Max. 51.5 (2.03)

SERVICE INFORMATION HCA-2500

120

140

160

180

100

91019

Ignition Air Gap Gauge

#.014 = .35mm

P/N 91004

Key Part Number Description Used for:

1 897801-33330 Tachometer PET-1000 Measuring engine speed to adjust carburettor

2 363018-00310 Washer Installing crankcase oil seal of starter side

3 433019-12330 Flange nut Removing magneto rotor (flywheel)

4 895612-79920 L-hex wrench (3 mm) Removing and installing hex. socket bolts (M4)

5 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolts (M5)

6 897701-06030 Bearing wedge Removing ball bearings on crankshaft

7 897701-14732 Bearing tool Removing and installing crankcase bearings

8 897702-30131 Piston pin tool Removing and installing piston pin (Use 8 mm dia. adapter)

9 897705-11520 Bearing tool Removing and installing con-rod small end needle bearing

10 897712-04630 2-pin wrench Removing and installing pawl carrier

11 897714-22830 Oil seal tool Installing ball bearing in gear case

12 897714-24330 Oil seal tool Installing crankcase oil seals

13 897726-09130 Oil seal tool Removing clutch drum and installing clutch drum ballbearing

14 91004 Module air gap gauge Adjusting pole shoe air gaps

15 897800-79931 Spark tester Checking ignition system

16 897803-30132 Pressure tester Checking carburettor and crankcase leakages

17 897835-16131 Pressure connector Checking crankcase and cylinder leakages

18 900100-08008 Bolt Removing magneto rotor (flywheel)

19 91007 Compression gauge Measuring cylinder compression

20 91019 Limiter cap tool Removing and installing limiter cap

1-6 Special tools

14: a=3mm

5 : a=4mm

236

78 910

11 12 14 15

16 18

17 20

SERVICE INFORMATIONHCA-2500 7

2 EMISSION ADJUSTMENT GUIDE

2-1 General adjusting rules

A. Before starting the unit for adjustment, check the following items.

1. The correct spark plug must be clean and properly gapped.

2. The air filter element must be clean and properly installed.

3. The muffler exhaust port must be clear of carbon.

4. The fuel lines, tank vent and fuel filter are in good condition and clear of debris.

5. The fuel is fresh ( > 89 octane : RON) and properly mixed at 50 : 1 with “ISO L-EGD”or “JASO FC”2-

stroke oil.

6. The gear case assembly with blade set adjusted clearance properly must be installed for proper engine

B. Set L and H mixture needles with limiter caps anticlockwise to rich side stop. Start and run engine for 2

minutes alternating engine speed between WOT and idle every 5 seconds. Adjust idle adjust screw to 2800

+/- 300 r/min.Adjust H mixture needle with limiter cap to 10000 +/- 500 r/min. If engine does not run correctly

after this adjustment, proceed to the next step (2-2).

C. After adjusting carburettor according to the steps 2-2 and 2-3, the limiter cap(s) must be installed on L

and/or H mixture needle(s) to comply with Emission Directive.

2-2 Presetting idle adjust screw, L mixture needle and H mixture needle

1. Remove cleaner lid. Turn the L and H mixture

needles anticlockwise to rich side stop and meet

limiter caps tabs (A) with locating slot (B), using 3

mm blade screw driver.

NOTE : If cap tabs (A) misalign with locating slots

(B), there is a chance to strip thread.

2. Screw left hand thread of limiter cap tool 91019

into centre hoIe of limiter cap anticlockwise until tab

of the limiter cap just come out from locating slot.

NOTE : DO NOT COMPLETELY REMOVE

LIMITER CAP FROM CARBURETOR! If the limiter

cap were pulled out completely, there is a chance

that the other mixture needle would turn and limiter

cap tab would misalign with locating slot when

screwing the limiter cap tool into centre hole of the

other limiter cap, and thread is stripped. When the

thread is stripped by limiter cap tool, screw 3 mm

wood screw in the stripped centre hole of the limiter

cap, and pull off the cap.

91019

(Continued)

(A)

(B)

(A)

SERVICE INFORMATION HCA-2500

3. Remove the limiter cap tool from the limiter cap

turning the tool clockwise, leaving the limiter cap in

place.

4. Screw threaded end of limiter cap tool 91019 into

centre hole of the other limiter cap anticlockwise until

the limiter cap is come out from the mixture needle

completely. Remove the limiter cap from limiter cap

tool turning clockwise. Screw thread of limiter cap

tool 91019 into centre hole of previous limiter cap to

pull out completely.

5. Turn idle adjust screw anticlockwise and set the

screw until the tip to just contact throttle plate. Then

turn idle adjust screw 1 1/2 turns clockwise. Install

removed cleaner lid.

6.Turn L and H mixture needle clockwise until lightly

seated, and then turn both mixture needles

anticlockwise following turns.

L mixture needle : 2 1/4,

H mixture needle : 3 1/4

NOTE : If needles are forced during seating, damage

to carburettor may occur.

2-2 Presetting idle adjust screw, L mixture needle and H mixture needle (continued)

91019

SERVICE INFORMATIONHCA-2500 9

2-3 Adjusting carburettor

1. Start engine and warm it up alternating engine

speed between WOT and idle every 5 seconds for

1 minute.

2. Using 2.5 mm wide blade screw driver, adjust L

mixture needle to obtain maximum idle speed.

3. Set idle speed in the range of 3,400 to 3,500

r/min by turning idle adjust screw.

4. Turn L mixture needle anticlockwise to reduce

engine idle speed 700 to 800 r/min to set idle speed

in the range of 2,600 to 2,800 r/min.

NOTE : Engine speed must be allowed to stabilize

a minimum of 20 seconds after each adjustment of

L mixture needle to assure accurate tachometer

readings.

5. Turn H mixture needle anticlockwise to reduce

engine speed to approx. 9,000 r/min at WOT.

6. Turn H mixture needle clockwise to obtain 9,500

to 10,500 r/min at WOT.

NOTE : During H mixture needle adjustment, do not

run engine at high speed without load longer than

10 seconds.

7. If the engine speed at WOT is above 10,500

r/min, adjust H mixture needle anticlockwise and set

maximum engine speed at less than 10,500 r/min.

idle adjust screw

(Continued)

SERVICE INFORMATION HCA-2500

2-3 Adjusting carburettor (Continued)

8.After adjusting carburettor, put new limiter cap on

the other side of limiter cap tool as shown, and press

the limiter caps to the bottoms on L and H mixture

needles respectively.

NOTE : Align the limiter cap’s tabs (A) with locating

slots (B) in extended housing of carburettor.

IMPORTANT : The limiter caps must be installed

L and H mixture needles to comply with

Emission Directive.

9. Start engine again and make sure engine runs

at idle speed in the range of 2,400 to 3,200 r/min

and at WOT engine speed in the range of 9,000 to

10,500 r/min. Also make sure blade would not move

at engine idle speed and suitable acceleration.

NOTE : Initial carburettor setting (Idle adjust screw,

L and H mixture needles) shown on page 3 and 8 is

to start the engine after restoration or carburettor

change. Idle adjust screw, L and H needles turn for

designated engine revolution through procedures

indicated here may vary. As long as idle and WOT

engine speed is set in given range, variance would

be ignorable.

(A)

(B)

(A)

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